Manuel Garcia

Experience

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  PDVSA Petroleos de Venezuela S.A.

  Jun 2005 - Nov 2006

  Reliability Engineer

  Responsible for managing and implementing the Bad Actor management program consisting of top opportunities identification, facilitation of RCA, and managing the Action Item Register. Responsible for providing RCA training to the Reliability work team members. Responsible for the equipment hierarchy and equipment criticality databases. Provide technical support to rotating equipment operation, repair, and rebuild such as centrifugal compressors and centrifugal pumps. Perform failure analysis for metals to identify failure mechanisms and support the RCAs. Some key achievements include: Updated and implemented the new bad actor management program based on improvement opportunities identification and RCA facilitation. Led and facilitated RCAs on top improvement opportunities and assisted in the identification of cost-effective actions to prevent recurrence. Savings: US$ 12 MM/year. Performed RBI study based on API RP 581 to fixed equipment of the crude and vacuum units resulting in a 10% reduction of the Turnaround scope of work. Savings: US$ 4 MM. Show less

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  PDVSA Petroleos de Venezuela S.A.

  Nov 2006 - Dec 2014

  Accountable for development and implementation of the Business Reliability Program. Responsible for the elimination of critical failure modes. Facilitate incident investigations of Process Safety Events. Responsible for optimizing frequencies and scopes of costly maintenance programs, such as turnaround and Inspection (T&I), and pipeline repairs. Conduct Probabilistic Risk Assessments and Life Cycle Cost Analyses aimed at optimizing assets’ life cycle. Responsible for developing and providing training to natural work teams in reliability methods such as RCA, RCM, Criticality Analysis, and Statistic for Reliability Engineering. Provide maintenance engineering support to critical rotating and fixed equipment. Oversee the Lubrication Management Program. Key Accomplishments: Led the API RP 581 quantitative RBI project to develop all fixed equipment (1,290), piping (11,822) and pressure relief devices (1,256). The main benefit was the reduction by 68% of the 10-year turnaround plan’s work scope, representing savings of approximately US$150 MM. Developed and implemented a methodology for optimizing the pipeline repair plan based on a probabilistic risk assessment through physics-of-failure-based reliability modeling resulting in a 50 % decrease of the 5-year strategic repair plan. Savings: US$13 MM. Developed RCM Asset Strategies for 37 highly critical pieces of rotating equipment (turboexpanders, turbogenerators, turbocompressors) based on SAE JA1012. Scope of work reduced by 25% despite creating 30% of new asset strategies. Led the turbomachinery bill of material project to improve spare parts management based on risk and identify alternative spare parts to OEM materials. Savings: US$1.1 MM Show less Responsible for managing and implementing the Bad Actor management program. Develop and implement a training program for mentoring and coaching RCA members and facilitators. Perform risk analysis to prioritize maintenance jobs and projects. Provide technical support to rotating equipment failure, repair, and rebuild such as gas turbines, centrifugal compressors, and centrifugal pumps. Provide training to natural work team members in RCA, Criticality Analysis, RCM, Reliability Engineering, SAP PM basis, and maintenance notifications processing in SAP.Some key achievements include: Developed and implemented the formal Bad Actor Management Program from the ground up producing a significant reduction of critical assets’ recurrent failures. Savings: US$ 18 MM/year. Instituted an operator driven reliability (ODR) program focusing on the operations role to enhance asset reliability for critical assets. Championed and established the lubrication management program for critical equipment, i.e.- turboexpanders, gas turbines, centrifugal and reciprocating compressors, generators, contributing to lubrication failure reduction by 20%. Show less

  • Reliability Section Head

    Dec 2008 - Dec 2014

  • Reliability Engineer

    Nov 2006 - Dec 2008
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  ASURADO Energy Consulting

  Dec 2014 - Jun 2015

  Technical Director Off Counselor

  • Coordinate and Lead optimization projects in Oil & Gas upstream, midstream and downstream facilities.• Provide Technical Assistance and Training during Reliability Program Implementations

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  Universidad Simón Bolívar

  Jan 2015 - Aug 2015

  Assistant Professor

  • Professor of Power Generation Subject - Undergraduate program for Electrical engineering Students

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  Yanbu Aramco Sinopec Refining Company (YASREF) Ltd.

  Jun 2015 - Aug 2018

  Reliability Engineer

  Responsible for identifying Bad Actors and Top-Opportunities based on Risk. Perform Asset Criticality Assessments (ACA). Facilitate Root Cause Analysis (RCA) using PROACT within Meridium and provide training and mentoring to the reliability work teams. Identify Asset Strategies thru Reliability Centered Maintenance (RCM) approach. Perform machinery diagnostics and process data analysis through System 1 and Pi. SME to critical rotating equipment failure, repair and rebuild, including Dry Gas Seals. Develop critical rotating equipment scopes of work. Develop and implement Reliability KPIs and data collection strategies. Guide Master Data correction and reliability data capture process improvements in SAP. Develop and oversee the Lubrication Management Program. Key Accomplishments: Led Preventive Maintenance Optimization (PMO) Project – Improved PM compliance from less than 70% to over 90% and was credited for enabling YASREF to receive Aramco Excellence Award for achieving the most improvement in Asset Availability Developed and implemented Bad Actor Management Program Established and led Hot Pumps Reliability Team – reduced seal failures by 92%, savings of $1.2 MM/year Led Spurious Trip Team, developed and implemented corrective actions– reduced spurious shutdowns by 30% Led the implementation of Critical Equipment Maintenance Readiness Process (Materials/Spares, Work scopes, Special Tools) Developed and implemented training programs for mentoring and coaching junior reliability and maintenance engineers Developed and conducted RCA Methodology training for users (Operations, Maintenance, Engineering) and facilitators (140 users, 14 facilitators) Show less

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  Bahrain Petroleum Company

  Sept 2018 - Dec 2021

  Reliability Specialist

  Responsible for driving the elimination of unplanned equipment downtime. Facilitate Root Cause Analysis and Incident Investigations in line with Process Safety Elements. Determine “Bad Actors” and Prioritize findings to focus on the biggest improvement opportunities. Confer with Subject Matter Experts (SME), Maintenance Leaders, and other Reliability Engineers to develop plans in partnership with Operations, Maintenance and Engineering (OME), to effectively and economically improve equipment and process designs. Responsible for reducing asset life cycle cost by partnering with the OME team to ensure focus on reliability and maintainability of new and modified equipment installations. Partner with OME teams to define, develop, and refine the Preventative/Predictive Maintenance program.Key Accomplishments: Performed Reliability, Availability, and Maintainability (RAM) and Life Cycle Cost (LCC) analyses to support the decision-making process of selecting a cost-effective system configuration of a new transfer pump system from the Tank Farm to the Wharf. The selection of the scenario with the lowest LCC represents project savings of around $1.3 MM. Show less

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  Aramco

  Dec 2021 - now

  Reliability Engineer

  Responsible for rotating equipment reliability, troubleshooting, and machinery diagnostics. Conduct root cause analysis to identify the causes of failure and recommend cost-effective solutions. Review and update maintenance strategies to optimize rotating equipment maintenance tasks. Develop/review rotating equipment repair procedures and work scopes in coordination with the workshops. Develop T&I scope and add any work if needed on rotating equipment during the T&I. Identify new technologies and techniques to assist the organization in shifting from a preventive mode into a proactive mode. Review/develop engineering request packages for any machinery modifications or upgrades. Oversee the PM, PdM, and RCM programs. Mentor junior reliability and maintenance technicians and engineers. Show less